mummdogg,
I have only replaced one panel on my truck, and it fit perfect. I have seen the comments about fitting the piece to the truck and am not sure I follow that approach.
When you do your floorboard/toe board, why can't you use your abrasive wheel to cut out sections following a nice straight line. It seems it would be easier to fit the new piece in, and would look much nicer.
You don't want to randomly chop stuff out of the way. Clean the material that will be removed, and make nice lines with a sharpie. Use a nibbler, or a abrasive wheel to dissect the piece following the lines.
I have seen your truck and know you have quite a bit of work ahead of you. Done properly, it will be fun and rewarding.
Did you ever decide on a little welder for this project?
Stuart
